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DE-102024132859-A1 - Layer structure, brake disc and process

DE102024132859A1DE 102024132859 A1DE102024132859 A1DE 102024132859A1DE-102024132859-A1

Abstract

The invention relates to a layer structure (1) comprising a carrier layer (4), a cover layer (5), and an intermediate layer (6) arranged between the carrier layer (4) and the cover layer (5), which is formed from a material (7) with a multiphase structure, wherein the cover layer (5) is kinetically sprayed, preferably by cold gas spraying.

Inventors

  • Wolfram Wagener
  • Florian Walther
  • Udo Dinglreiter
  • Andreas Mössner
  • Christian Judex

Assignees

  • BAYERISCHE MOTOREN WERKE AKTIENGESELLSCHAFT
  • INACORE GmbH

Dates

Publication Date
20260513
Application Date
20241111

Claims (13)

  1. Layer structure (1), comprising a carrier layer (4), a cover layer (5) and an intermediate layer (6) arranged between the carrier layer (4) and the cover layer (5), which is formed from a material (7) with a multiphase structure, characterized in that the cover layer (5) is kinetically sprayed.
  2. Layer structure (1) according to Claim 1 , characterized in that the top layer (5) is cold gas sprayed.
  3. Layer structure (1) according to Claim 1 or 2 , characterized in that the multiphase structure is a two-phase structure.
  4. Layer structure (1) according to one of the preceding claims, characterized in that the material (7) of the intermediate layer (6) is duplex steel (11).
  5. Layer structure (1) according to one of the preceding claims, characterized in that a thickness (12) of the intermediate layer (6) is at least 50 micrometers and/or at most 350 micrometers.
  6. Layer structure (1) according to one of the preceding claims, characterized in that the material (7) of the intermediate layer (6) has a PREN number greater than 27.
  7. Layer structure (1) according to one of the preceding claims, characterized in that the material (7) of the intermediate layer (6) has a yield strength greater than 450 megapascals.
  8. Layer structure (1) according to one of the preceding claims, characterized in that the top layer (5) and the intermediate layer (6) are produced by different coating processes.
  9. Layer structure (1) according to Claim 8 , characterized in that the intermediate layer (6) is applied to the carrier layer (4) by means of laser powder deposition welding, preferably laser powder high-speed deposition welding.
  10. Layer structure (1) according to one of the preceding claims, characterized in that the cover layer (5) is formed at least partially from metal (16), ceramic and/or a carbide.
  11. Layer structure (1) according to one of the preceding claims, characterized in that the cover layer (5) has embedded hard material particles (17) which are formed in particular from a carbide or from ceramics.
  12. Brake disc (3) for a braking device, in particular of a motor vehicle, with a layer structure (1) according to one of the preceding claims.
  13. Method for producing a layer structure (1) in which a carrier layer (4) is coated with an intermediate layer (6) which is formed from a material (7) with a multiphase structure, characterized in that the intermediate layer (6) is coated with a top layer (5) by means of kinetic spraying, preferably cold gas spraying.

Description

The invention relates to a layer structure according to the preamble of claim 1. Furthermore, the invention relates to a brake disc for a brake device with such a layer structure and a method for producing a layer structure according to the preamble of claim 13. The WO 2023 / 186 347 A1 Disclosing a brake disc for a friction brake of a motor vehicle, comprising a friction section with at least one friction surface and a mounting section for wheel-side attachment to the motor vehicle, wherein the friction section and the mounting section are formed on a base body made of gray cast iron or steel, and wherein a wear-resistant layer is thermally applied to the friction section as a friction surface, and wherein a hard interlayer is arranged between the wear-resistant layer and the base body, via which the wear-resistant layer is bonded to the base body. The object of the invention is to create a layer structure, a brake disc for a braking device and a method for producing a layer structure, in such a way that the wear resistance of the layer structure can be particularly increased. This problem is solved according to the invention by a layered structure with the features of claim 1, by a brake disc for a braking device with the features of claim 12, and by a method for producing a layered structure with the features of claim 13. Advantageous embodiments of the invention are the subject of the dependent claims and the description. A first aspect of the invention relates to a layered structure, particularly for a component. The layered structure can be referred to as a layered system. For example, the component, particularly in its fully manufactured state, has the layered structure. The component in question is, for example, a vehicle component, specifically a motor vehicle component. Therefore, the component can be a component for a vehicle, particularly a motor vehicle. The motor vehicle is, for example, a car, specifically a passenger car. The layer structure can thus be intended for use in the motor vehicle. Alternatively, the layer structure can be intended for other applications. The layer structure includes at least one support layer, which can be referred to as the first layer. Thus, the layer structure can have the support layer as the first layer. The support layer is, for example, made of a cast material. In other words, the support layer is produced by casting. It can therefore be intended that the support layer is produced by casting. Furthermore, the layer structure comprises at least one cover layer, which is distinct from the carrier layer and can be referred to as the second layer. The layer structure also comprises at least one intermediate layer, which is distinct from the carrier layer and the cover layer and can be referred to as the third layer. This intermediate layer is arranged, in particular directly, between the carrier layer and the cover layer and can be referred to as the third layer. In other words, the intermediate layer extends at least partially, in particular predominantly or completely, between the carrier layer and the cover layer. This means that the carrier layer and the cover layer are connected to each other via the intermediate layer, in particular directly. Thus, the layer structure comprises, in particular, several layers, which can be the first layer, the second layer, and the third layer. The intermediate layer is formed, in particular at least partially, predominantly, or completely, from at least one material with a multiphase microstructure. This means that the material of the intermediate layer exhibits the multiphase microstructure. In other words, the intermediate layer has the multiphase microstructure. The microstructure can be understood, in particular, as the microstructure of the material. The microstructure can describe the arrangement and order of the material's constituents at the visible and microscopic levels. In particular, the term microstructure denotes the characteristics of a whole of those partial volumes, each of which is homogeneous in its composition and spatial arrangement of its constituents with respect to a fixed axis system placed within the material. In particular, the microstructure is characterized by the type, shape, size, distribution, and/or orientation of its constituents. The material is, for example, a metal, preferably steel. The material can therefore be steel with a multiphase microstructure. In order to particularly increase the wear resistance of the layer structure, especially of the component comprising the layer structure, it is provided according to the invention that the top layer is or is kinetically sprayed, for example at a speed of More than 300 meters per second. In other words, at least one manufacturing step for producing the top layer or layer structure includes a kinetic spraying process. Therefore, it is specifically intended that the intermediate layer is coated with the top layer using a kinetic spraying pr